Figure Title Page - Robinson R44

CHAPTER 99

SPECIAL TOOLS

Figure Title Page

99-1 Field Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.1

99-3 R44 Technical Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.3

99-5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.4

99-7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.6

99-9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.8

99-11 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.10

99-13 Pop-Out Float Cylinder Assembly Tools . . . . . . . . . . . . . . . . . . . . . . 99.12

99-15 Shipping Crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.14

99-17 Shipping Crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.16

FEB 2020 Chapter 99 Special Tools Page 99.i

Intentionally Blank

Page 99.0 Chapter 99 Special Tools FEB 2020

FIELD KITS*

99-1-1 R7983 R44-series C017-5 Swashplate Installation Field Kit

2 KI-4401 R44-series Minimum Spare Parts Kit Instructions

3 KI-4402 R44 (Raven I & Clipper I) 2200-Hour Inspection Kit Instructions

4 KI-4403 R44 II (Raven II & Clipper II) 2200-Hour Inspection Kit Instructions

5 KI-4405 R44 O-540 Engine Installation Provisions Kit & Instructions

6 KI-4406 R44 II IO-540 Engine Installation Provisions Kit & Instructions

7 KI-4407-1 R44-series Interior Furnishings Installation Kit Instructions (Velour)

8 KI-4407-2 R44-series Interior Furnishings Installation Kit Instructions (Leather)

NOTES * See www.robinsonheli.com for the latest kit contents.

FEB 2020 Chapter 99 Special Tools Page 99.1

Intentionally Blank



R44 TECHNICAL PUBLICATIONS

99-3-1 R7204 R44 Maintenance Manual (Incl items 2 thru 4) . . . . . . . . . . . . X 1

2 R7205 R44 Maintenance Manual — Binder . . . . . . . . . . . . . . . . . . . . X 1

3 R7211 R44 Maintenance Manual — Tabs . . . . . . . . . . . . . . . . . . . . . X 1

4 R7207 R44 Maintenance Manual — Inserts . . . . . . . . . . . . . . . . . . . . O 1

***

5 R7281 R44 Illustrated Parts Catalog (Incl items 6 thru 8) . . . . . . . . . X 1

6 R7216 R44 Illustrated Parts Catalog — Binder . . . . . . . . . . . . . . . . . . X 1

7 R7214 R44 Illustrated Parts Catalog — Tabs . . . . . . . . . . . . . . . . . . . X 1

8 R7215 R44 Illustrated Parts Catalog — Insert . . . . . . . . . . . . . . . . . . O 1

***

9 R8656 Maintenance Record — Binder . . . . . . . . . . . . . . . . . . . . . . . . X 1

10 R8650 Maintenance Record — Tabs . . . . . . . . . . . . . . . . . . . . . . . . . X 1

11 R8478 Maintenance Record — Insert (Incl item 12) . . . . . . . . . . . . . . X 1

12 R8479 Maintenance Record — Component Cards (pack of 20) . . . . . X 1

***

13 R7282 R44 POH (Incl items 14 thru 16) . . . . . . . . . . . . . . . . . . . . . . X 1

14 R7219 R44 POH — Binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

15 R7226 R44 POH — Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

16 R7218 R44 POH — Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O 1

***

17 R8188 R44 II POH (Incl items 18 thru 20) . . . . . . . . . . . . . . . . . . . . . X 1

18 R8189 R44 II POH — Binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

19 R7226 R44 II POH — Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

20 R8190 R44 II POH — Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O 1

***

21 R8670 R44 Cadet POH (Incl items 22 thru 24) . . . . . . . . . . . . . . . . . X 1

22 R8671 R44 Cadet POH — Binder . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

23 R7226 R44 Cadet POH — Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

24 R8672 R44 Cadet POH — Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . O 1

NOTES

Page 99.4 FIGURE 99-5 SPECIAL TOOLS FEB 2020


NOTES * No longer available.

SPECIAL TOOLS

99-5-1 MT548-1 Engine Hoist Adapter (includes fitting, bolt, washers and nuts) X 1MT548-7 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1NAS6604-17 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 2NAS1149F0432P Washer ([1] under head, [1] under nut) . . . . . . . . . . . . . . . . . X 4D210-4 Nut (or MS21042L4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 2

2 MT525-1 Main Rotor Rigging Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . X 13 MT525-2 Tail Rotor Rigging Fixture (includes clip and [2] screws) . . . . . X 1

MT050-8 Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 191251A144 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 2

4 MT122-6 Main Rotor Hub Bolt Stretch Measuring Tool (includes MT200-1 indicator and attaching hardware) . . . . . . . . . . . . . X 1

MT200-1 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1MS27039C0809 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1NAS1149FN832P Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1MS21042L08 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

5 MT053-1 Main Rotor Gearbox Drain Valve Tool (use only with old-style A7260* chip detector) . . . . . . . . . . . . . . . . . . . . . . . . . X 1

6 MT054-1 Main Rotor Gearbox Drain Valve Tool (use only with B566-1 “quick release” chip detector) . . . . . . . . . . . . . . . . . . . . . . . . X 1

7 MT526-1 Main Rotor Blade Trim Tab Bender (C016-2 AND C016-5 STAINLESS STEEL BLADES ONLY) . . . . . . . . . . . . . . . . . . . . X 1

MT526-8 Main Rotor Blade Trim Tab Bender (C016-7 ALUMINUM BLADES ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

8 MT091-1 Engine Ring Gear Holder Assembly (Incl items 9 thru 11) . . . . X 19 AN316-4 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O 2

10 NAS6604-19 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 211 MT091-3 Decal (“Caution: Torque nuts to 100 in-LB...”) . . . . . . . . . . . X 112 MT592-1 Fan Puller (Incl item 13 and [6] NAS6605-16 bolts) . . . . . . . . X 113 MT092-3 Spacer (Rev. H, 1.200-inches long) . . . . . . . . . . . . . . . . . . . . X 6 14 MT121-1 Bracket Assembly – Magnetic Pickup . . . . . . . . . . . . . . . . . . X 115 60297-10 O-540 & IO-540 Engine Operator’s Manual (Lycoming part

no.; available online at www.lycoming.com) . . . . . . . . . . . . . O 116 MT146-4 Blocks – Lower Swashplate Rigging (Set of [2]; use with

F198-1 swashplate.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 117 MT146-3 Blocks – Lower Swashplate Rigging (Set of [2]; use with

C198-2 swashplate.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 118 MT146-2 Blocks – Lower Swashplate Rigging (Set of [2]; use with

C198-1 swashplate.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 119 MT357-9 Taper Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1



SPECIAL TOOLS

99-7-1 MT173-5 Torque Wrench Extension Tool Set – Fan Nut (R22 and R44; includes items 2 thru 6; no longer available) . . . . . . . . . . . . . . . O 1

2 MT173-6 Torque Wrench Welded Assembly (no longer available) . . . . . . O 1

3 MT173-9 Extension Bar (3/4” drive, 8“ length) . . . . . . . . . . . . . . . . . . . . X 1

4 MT173-7 Socket (3/4” drive, 1-1/2” 12 pt) . . . . . . . . . . . . . . . . . . . . . . . X 1

5 MT173-4 Socket (3/4” drive, 1-11/16” 12 pt) . . . . . . . . . . . . . . . . . . . . . X 1

6 MT173-8 Socket (3/4” drive, 2” 12 pt) . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

7 MT147-1 Air Bleed Tool Assembly – Main Rotor Spindle . . . . . . . . . . . . . X 1

8 MT252-1 Bearing Pressing Tool – Tail Rotor Hub . . . . . . . . . . . . . . . . . . . X 1

9 MT549-2 Flat Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

10 MT549-1 Spacer – Spindle Boot Adjustment . . . . . . . . . . . . . . . . . . . . . X 2

11 MT527-1 Helicopter Lifting Fixture (Incl item 12) . . . . . . . . . . . . . . . . . X 1

12 MT527-5 Bushing (nylon; type 6/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 4

13 MS16633-2018 Retaining Ring ([3] required for removal or installation of collective spring assembly. Not for in-flight use. See also Figure 67-25.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 3

14 MT544-2 Spring Retainer – Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

15 MT352-1 Main Rotor Blade Trim Tab Gage (includes MT200-1 dial indicator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

MT200-1 Dial Indicator (dial indicator only) . . . . . . . . . . . . . . . . . . . . . . . X 1

16 MT547-1 Cyclic Trim Set-Up Box (no longer available) . . . . . . . . . . . . . O 1

17 MT357-4 Hex Driver (FABL8*; 3/8” square drive) . . . . . . . . . . . . . . . . . X 1

18 MT357-8 Nipple Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

19 MT357-5 Torque Adapter (FRDH101*; 3/8” square drive) . . . . . . . . . . X 1

20 MT559-1 Blocks – Main Rotor Rigging (set; holds cyclic in neutral position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

21 MT357-6 Wrench – Open End (3/8” & 7/16”; LTA1214*) . . . . . . . . . . . . . X 1

22 MT357-7 Wrench – Box End (7/32” & 1/4”; XDH78A*) . . . . . . . . . . . . . X 1

23 MT516-1 Valve Spring Compressor Tool . . . . . . . . . . . . . . . . . . . . . . . . . X 1

24 MT133-5 Engine Valve Clearance Check Tool (angle valve) . . . . . . . . . . . X 1

25 MT133-1 Engine Valve Clearance Check Tool (parallel valve) . . . . . . . . . . X 1

26 MT133-9 Adapter Assembly (used with items 24 and 25) . . . . . . . . . . . . X 1

NOTES * Snap-On part no.



NOTES

SPECIAL TOOLS

99-9-1 MT528-1 Clutch Bearing (C184) Removal/Installation Tool (For use with hydraulic press.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

2 MT528-2 Clutch Bearing (C184) Removal/Installation Tool (For use when hydraulic press is not available; order also item 1.) . . . . X 1

3 MT354-7 Teeter Moment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

4 MT357-3 Drill Bit (steel, cobalt; 0.156 in. dia.) . . . . . . . . . . . . . . . . . . . X 1

5 MT357-2 Reamer (0.375 in. dia.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

6 MT260-6 Tail Rotor Drive Shaft Runout Indicator Kit . . . . . . . . . . . . . . . X 1

MT260-5 Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

MT260-2 Extension (1.00 inch long) . . . . . . . . . . . . . . . . . . . . . . . . . . . X 3

MT260-3 Extension (2.00 inches long) . . . . . . . . . . . . . . . . . . . . . . . . . X 2

7 MT331-4 Sheave Alignment Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

8 MT329-10 Tube – Press Extension (used with items 9 and 10) . . . . . . . . X 1

9 MT329-6 Plug (MR hub bearing installation) . . . . . . . . . . . . . . . . . . . . . X 1

10 MT643-1 Support (MR hub bearing installation) . . . . . . . . . . . . . . . . . . X 1

11 MT359-1 Spring Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

12 MT569-2 Guide Assembly – Drill (main rotor hub nut) . . . . . . . . . . . . . . X 1

13 MT384-1 Hydraulic Test Pump (U.S. / Canada / Mexico – 110 V) . . . . . X 1

MT384-2 Hydraulic Test Pump (Outside North America – 220 V) . . . . . X 1

14 MT340-1 Float Gage and Fill Gun Kit (Incl items 15, 17, and [2] MS35489-40 grommets; not shown) . . . . . . . . . . . . . . . . . . X 1

15 MT340-2 Airgun Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

16 MT401-1 Topping Valve Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

17 MT340-3 Gage Assembly (Incl item 18) . . . . . . . . . . . . . . . . . . . . . . . . X 1

18 MT340-4 Decal (air pressure gage instructions) . . . . . . . . . . . . . . . . . . . X 1



NOTES

SPECIAL TOOLS

99-11-1 MT556-11 Kit – Tail Rotor Elastomeric Bearing Removal and Installation Tools (Incl items 2 thru 5; no longer available.) . . . . . . . . . . . O 1

2 MT556-15 Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O 1

3 MT556-16 Cap (R44 and R66) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

4 MT556-12 Mandrel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O 1

5 AN6-34A Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

6 MT556-17 Kit – Tail Rotor Elastomeric Bearing Removal and Installation Tools (Incl items 3, 7 thru 11) . . . . . . . . . . . . . . . . . . . . . . . . X 1

7 MT556-18 Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

8 MT556-6 Cap (R22; not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

9 MT556-19 Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

10 NAS6604-26 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

11 NAS6604-36 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

12 B361-2 Bearing (Ref; see Figure 64-5)

13 D062-2 Tail Rotor Hub (Ref; see Figure 64-5)

Page 99.12 FIGURE 99-13 POP-OUT FLOAT CYLINDER ASSEMBLY TOOLS FEB 2020


NOTES * Refer to R44 Service Bulletin SB-80.

** Order KI-211 to replace.

POP-OUT FLOAT CYLINDER ASSEMBLY TOOLS*

99-13-1 MT546-1 Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

2 D757-1** Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O 1

3 MT545-1 Pin Assembly (Ref; see Figure 32-13)

4 D679-3 Cylinder Assembly (Ref; see Figure 32-13)

5 D767-7 Fill-port cap (Ref)

6 MT546-6 Bleed Fitting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

7 MS28778-2 Packing (o-ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

8 MT546-2 Adapter Assembly (Incl item 7) . . . . . . . . . . . . . . . . . . . . . . . X 1

9 — Fill Hose (Ref)

10 KI-151 Cylinder Bleed-off Kit (Incl items 1, 3, 6 thru 8) . . . . . . . . . . . X 1

Page 99.14 FIGURE 99-15 SHIPPING CRATES FEB 2020


SHIPPING CRATES*

99-15-1 R5384 Main Rotor Gearbox Crate (90” X 24” X 27”, 265 lbs) . . . . . . X 1

2 R5385 Push-Pull Tube/Tail Rotor Drive Shaft Crate (192” X 11” X 16”, 165 lbs; holds [4] push/pull tubes or [4] TR driveshafts) X 1

3 R5386 Cabin Door Crate (60” X 34” X 23”; 25 lbs; holds [1] bubble or [2] regular doors) . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

4 R5170 Windshield Box (63” X 40” X 17”; 45 lbs; cardboard. Holds up to [3] windshields.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

5 R5352 Main Rotor Blade Crate (207” X 17” X 21”; 390 lbs) . . . . . . . X 1

6 R5388 Tailcone Crate (194” X 24” X 28”; 290 lbs) . . . . . . . . . . . . . X 1

NOTES * Dimensions are approximate and expressed in inches. Dimensions given describe length, width, and height. Weight stated is approximate and includes crate and contents.

Page 99.16 FIGURE 99-17 SHIPPING CRATES FEB 2020


SHIPPING CRATES*

99-17-1 R5702 Main Rotor Blade [2] / Tailcone [1] Crate (208” X 30” X 29”; 695 lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X 1

2 MT899-1 Tow Cart Crate (67” X 38” X 31”; 572 lb) . . . . . . . . . . . . . . . X 1

3 R7423 Float Crate (172” X 45” X 22”; 485 lb) . . . . . . . . . . . . . . . . . X 1

NOTES * Dimensions are approximate and expressed in inches. Dimensions given describe length, width, and height. Weight stated is approximate and includes crate and contents.

Intentionally Blank


Documents

Figure Title Page - Robinson R44